Ultrasonic Bonding Tool Protrusions Prevent Resin Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ultrasonic bonding of synthetic resin sheets in layered batteries is hindered by adhesion of molten resin to knurled protrusions on the horn and anvil, leading to the workpiece becoming affixed, which complicates the joining process.
Innovation Solution
The ultrasonic bonding tool features quadrangular pyramid protrusions with apex angles between 110-130°, which suppress adhesion by reducing localized biting into the resin sheets and minimizing the force component that causes adhesion during resin shrinkage, and optionally includes a non-adhesive coating for further reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If knurled protrusions are used on the ultrasonic bonding tool, then bonding strength is improved, but molten resin adheres to the protrusions causing workpiece affixation
Solution Approach 1:
The invention changes the geometric parameters of the protrusions by specifying a particular apex angle range (110-130 degrees). This parameter modification alters how the protrusions interact with the resin material during ultrasonic bonding, reducing adhesion while preserving bonding effectiveness.
Solution Approach 2:
The invention applies a non-adhesive coating to the surface of the protrusions. This creates a localized property difference where the coating layer prevents resin adhesion while the underlying protrusion structure maintains bonding capability.
2Ease of manufacture
If portions devoid of heat-resistant layer are formed to enable joining, then ultrasonic bonding becomes possible, but adhesion to protrusions occurs during the process
Solution Approach 1:
The invention modifies the geometric parameters of the protrusions (apex angle of 110-130 degrees) to change the interaction dynamics between the tool and molten resin, thereby preventing adhesion while maintaining the ability to join separators with and without heat-resistant layers.
Solution Approach 2:
The non-adhesive coating acts as an intermediary layer between the protrusion surface and the molten resin. This coating prevents direct contact and adhesion between the resin and tool surface, allowing the bonding process to proceed without workpiece affixation.
3Strength
If protrusions bite into synthetic resin sheets for bonding, then bonding strength increases, but adhesion force increases causing workpiece affixation
Solution Approach 1:
The invention optimizes the apex angle parameter of the protrusions to a specific range (110-130 degrees). This geometric parameter change reduces the adhesion force component while preserving sufficient biting action to achieve strong bonding between resin sheets.
Solution Approach 2:
The non-adhesive coating is applied locally to the protrusion surfaces where contact with molten resin occurs. This creates a localized non-adhesive zone that eliminates workpiece affixation while maintaining the protrusions' ability to bite into and bond resin sheets.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively prevents the workpiece from adhering to the tool, enhancing bonding efficiency by minimizing adhesion and ensuring reliable separation of the resin layers without compromising the breaking of heat-resistant layers.
Implementation Method 1
ultrasonic bonding tool provided with protrusions used on a horn side of an ultrasonic bonding device
Implementation Method 2
protrusions shaped as quadrangular pyramids having a flat top surface, and each of the protrusions has an angle within a range of 110°-130°, with the angle being an apex angle formed by two mutually opposite side surfaces
Implementation Method 3
protrusions shaped as quadrangular pyramids having a flat top surface, and each of the protrusions has an angle within a range of 110°-130°, with the angle being an apex angle formed by two mutually opposite side surfaces from among four side surfaces
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A tip (24) on which a plurality of protrusions (31) are formed in a regular pattern is provided to a horn (23) side of an ultrasonic bonding device (21). Each of the protrusions (31) is shaped as a square pyramid having four side surfaces (31a, 31b, 31c, 31d) and a flat top surface (31e). An apex angle (α) formed by two mutually opposite side surfaces is greater than 90°, e.g., is 120°. When two separators (1) of a battery cell are joined together, a force with which the separators (1) adhere to the protrusions (31) is weak, and the separators (1) do not adhere to the horn (23).